High speed robotic product collation and loading system

ABSTRACT

A product collation and loading system collates products into a proper pack pattern and loading the product into a load station or container. The system includes a grouping robot for separating group counts and holding incoming product while the sweep arm begins its cycle. The grouping robot may be positioned upstream of the sweeping robot. The sweeping robot pushes groups of product from the loading station and may act as overhead containment where the product is decelerated. The sweeping robot may be positioned between the grouping robot and a dynamic backstop. The dynamic backstop may be used to position the leading product in the correct location for the sweeping robot and may also decelerate the product to reduce impact. The dynamic backstop may be positioned directly downstream of the sweeping robot. The system may also include a reject cylinder for lifting an arm of the dynamic backstop to allow improperly oriented/located product to pass.

BACKGROUND OF THE INVENTION

The present invention relates to packaging systems and, more particularly, to an apparatus and method for collating products into a proper pack pattern and loading the product into a box.

It is difficult to group and package products that are produced at high rates of speed. Most conventional collation and loading systems have difficulty handling products that are produced at a high rate of speed.

As can be seen, there is a need for a product collation and loading system that can handle product moving at high rates of speed.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a collation and loading system for collating and loading product comprises a grouping robot adapted to group product into predetermined groups; a sweeping robot adapted to push grouped product into a loading area or container; and a dynamic backstop adapted to position the grouped product in a sweep position to be pushed by the sweeping robot.

In another aspect of the present invention, a method for collating and loading product comprises conveying product along a conveyor; grouping product into predetermined groups with a grouping robot; positioning the grouped product in a sweep position with a dynamic backstop; and pushing the grouped product from the sweep position into a loading area.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a product collation and loading system according to an exemplary embodiment of the present invention;

FIG. 2 is a side elevation view of the product collation and loading system of FIG. 1, in use;

FIG. 3 is a side elevation view of the product collation and loading system of FIG. 1;

FIG. 4 is an isometric view of a sweeping element used in the product collation and loading system of FIG. 1; and

FIG. 5 is a plan view of a dynamic backstop element used in the product collation and loading system of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Various inventive features are described below that can each be used independently of one another or in combination with other features.

Broadly, an embodiment of the present invention provides a product collation and loading system for collating products into a proper pack pattern and loading the product into a box. The system includes a grouping robot for separating group counts and holding incoming product while the sweep arm begins its cycle. The grouping robot may be positioned upstream of the sweeping robot. The sweeping robot pushes groups of product off of the infeed system and may act as overhead containment where the product is decelerated. The sweeping robot may be positioned between the grouping robot and a dynamic backstop. The dynamic backstop may be used to position the leading product in the correct location for the sweeping robot and may also decelerate the product to reduce impact. The dynamic backstop may be positioned directly downstream of the sweeping robot. The system may also include a reject mechanism to allow improperly oriented/located product to bypass the collation/loading system.

Referring to FIGS. 1 through 5, a product collation and loading system 10 (also referred to as system 10) may include a conveyer belt 12 for carrying product 14.

The product 14 may first encounter a grouping robot 16. The grouping robot 16 may separate groups of product 14 according to a specific product count by holding the product with the end effecter 22.

Once grouped by the grouping robot 16, the product may pass to a sweeper robot 24. The sweeper robot 24 may control a sweeper arm 30 used to move product into a loading station or container. The sweeper robot 24 may be positioned between the grouping robot 16 and a dynamic backstop 32. As a backstop member 40 of the dynamic backstop 32 collects the product, the sweeper arm 30 of the sweeper robot 24 is positioned perpendicular to the conveyor and opposite the loading station side. When the dynamic backstop reaches the correct position and the product count is correct, the sweeper arm 30 of the sweeper robot 24 may sweep horizontally across the conveyor 12. This action may move the product 14 from the conveyor 12 into the loading station or container. As the sweeper arm 30 returns to its home position, it may stop over the product 14 being collected by the dynamic backstop 32. This may aid in containing the product between the dynamic backstop 32, the grouping robot 16 and the conveyor 12. Once the required amount of product 14 is collected by the dynamic backstop 32 and the dynamic backstop 32 is in the correct location, the sweeper arm 30 may sweep the product 14 to the loading station or container. In one exemplary embodiment, the dynamic backstop 32 may be moved via a carriage 42 driven by a belt 44.

The dynamic backstop 32 may be constructed such as to cause the deceleration of product on the infeed system. A reject mechanism 36, 38 may be part of the assembly. As product 14 approaches the identified load area at a high rate of speed, the dynamic backstop 32 may move in an upstream direction to engage with the product. At a defined location and time, the dynamic backstop 32 begins to move in a downstream direction toward the edge of the loading station. With this motion, the dynamic backstop 32 may be used to position the leading product 14 in the correct location for the sweeper robot 24 and may also decelerate the product 14 to reduce impact. The dynamic backstop 32 stops at a location which properly lines up the product 14 for the sweeper robot 24. The dynamic backstop 32 stays in this position until the end effecter 22 of the grouping robot 16 groups the product 14 according to the specified product count and the sweeper arm 30 of the sweeper robot 24 sweeps the product from the infeed system. When the sweeper arm 30 of the sweeper robot 24 has moved the product from the infeed system, the dynamic backstop 32 again moves in an upstream direction and positions itself to a defined location to engage with the product.

In summary, the product may travel on the conveyor 12 and may be decelerated by the dynamic backstop 32. The grouping robot 16 may drop between the last product of the current product group and the first product of the next product group and may then move downstream to properly collate the current group. When the grouping robot 16 and the dynamic backstop 32 reach their correct positions, the sweeping robot 24 then sweeps the product off the infeed system and into the load station, using the grouping robot 16 and dynamic backstop 32 to contain the product. The grouping robot 16 then ascends and releases the product where they continue on until they reach the dynamic backstop 32. The sweeping arm 30 may rise over the product and be positioned above the product to act as overhead containment prior to the backstop 32 completing its stroke. The grouping robot 16 may then come down to separate the product groups as before. This cycle repeats continuously to collate the product groups.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. 

1. A collation and loading system for collating and loading product, the system comprising: a grouping robot adapted to group product into predetermined groups; a sweeping robot adapted to push grouped product into a loading area; and a dynamic backstop adapted to position the grouped product in a sweep position to be pushed by the sweeping robot.
 2. The system of claim 1, further comprising a conveyor for moving the product through the system.
 3. The system of claim 1, wherein the grouping robot includes an end effecter adapted to be positioned between products moving on a conveyor to separate the product into product groups.
 4. The system of claim 3, wherein the grouping robot includes a system for keeping the end effecter horizontal during movement.
 5. The system of claim 1, wherein the sweeper robot includes: a sweeper arm adapted to be positioned over the product to act as an overhead containment, the sweeper arm further adapted to push product off a conveyor into the loading area; and a system for keeping the sweeper arm horizontal during movement.
 6. The system of claim 1, wherein the dynamic backstop includes a backstop arm lifted by a cylinder to reject and allow product to continue downstream on a conveyor.
 7. A method for collating and loading product, the method comprising: conveying product along a conveyor; grouping product into predetermined groups with a grouping robot; positioning the grouped product in a sweep position with a dynamic backstop; and pushing the grouped product from the sweep position from the loading station.
 8. The method of claim 7, further comprising decelerating the product with the dynamic backstop. 